GENERAL INFORMATION How to use this Manual: (w) Range of Topics • • This manual contains procedures for performing all required service operations. The procedures are divided into the following five basic operations: Removal/Installation Disassembly/Assembly Replacement Inspection Adjustment Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of parts, jacking, vehicle lifting, cleaning of parts, and visual inspection) have been omitted.
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Symbols • There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols show application points or use of these materials during service.
Advisory Messages • You will find several Warnings , Cautions , Notes , Specifications and Upper and Lower Limits in this manual. Warning • A Warning indicates a situation in which serious injury or death could result if the warning is ignored. Caution • A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored. Note • A Note provides added information that will help you to complete a particular procedure.
Troubleshooting Procedure Basic flow of troubleshooting DTC troubleshooting flow (on-board diagnostic) • • Diagnostic trouble codes (DTCs) are important hints for repairing malfunctions that are difficult to simulate. Perform the specific DTC diagnostic inspection to quickly and accurately diagnose the malfunction. The on-board diagnostic function is used during inspection.
Quick diagnosis chart (If mentioned) • The quick diagnosis chart lists diagnosis and inspection procedures to be performed specifically relating to the cause of the malfunction. Symptom troubleshooting • Symptom troubleshooting quickly determines the location of the malfunction according to symptom type. Procedures for Use Using the basic inspection (section 05) • • • • Perform the basic inspection procedure before symptom troubleshooting. Perform each step in the order shown.
Using the DTC troubleshooting flow • DTC troubleshooting flow shows diagnostic procedures, inspection methods, and proper action to take for each DTC.
Using the diagnostic index • • The symptoms of the malfunctions are listed in the diagnostic index for symptom troubleshooting. The exact malfunction symptoms can be selected by following the index.
Using the quick diagnosis chart • • • The chart lists the relation between the symptom and the cause of the malfunction. The chart is effective in quickly narrowing down the relation between symptom and cause of the malfunction. It also specifies the area of the common cause when multiple malfunction symptoms occur. The appropriate diagnostic inspection relating to malfunction cause as specified by the symptoms can be selected by looking down the diagnostic inspection column of the chart.
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SERVICE CAUTIONS Protection of the Vehicle • Always be sure to cover fenders, seats and floor areas before starting work. Preparation of Tools and Measuring Equipment • Be sure that all necessary tools and measuring equipment are available before starting any work. Special Service Tools • Use special service tools or equivalent when they are required.
WARNING: • For vehicles with DSC, if the negative battery cable is disconnected, the stored initial position of the steering angle sensor will be cleared and the DSC will not operate properly, making the vehicle unsafe to drive. Perform the steering angle sensor initialization procedure after connecting the negative battery cable.
6. Check the area where the oil is leaking, then make necessary repairs. Removal of Parts • While correcting a problem, also try to determine its cause. Begin work only after first learning which parts and subassemblies must be removed and disassembled for replacement or repair. After removing the part, plug all holes and ports to prevent foreign material from entering.
Arrangement of Parts • All disassembled parts should be carefully arranged for reassembly. • Be sure to separate or otherwise identify the parts to be replaced from those that will be reused. Cleaning of Parts • All parts to be reused should be carefully and thoroughly cleaned in the appropriate method. WARNING: • Using compressed air can cause dirt and other particles to fly out causing injury to the eyes. Wear protective eye wear whenever using compressed air.
Cotter pins Nylon nuts Depending on location: • Sealant and gaskets, or both, should be applied to specified locations. When sealant is applied, parts should be installed before sealant hardens to prevent leakage. Oil should be applied to the moving components of parts. Specified oil or grease should be applied at the prescribed locations (such as oil seals) before reassembly. Adjustment • Use suitable gauges and testers when making adjustments.
Hose Clamps • When reinstalling, position the hose clamp in the original location on the hose and squeeze the clamp lightly with large pliers to ensure a good fit. Torque Formulas • When using a torque wrench- SST or equivalent combination, the written torque must be recalculated due to the extra length that the SST or equivalent adds to the torque wrench. Recalculate the torque by using the following formulas. Choose the formula that applies to you.
Vise • When using a vise, put protective plates in the jaws of the vise to prevent damage to parts. Dynamometer • When inspecting and servicing the power train on the dynamometer or speed meter tester, pay attention to the following: Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle. Make sure the vehicle is in a facility with an exhaust gas ventilation system. Since the rear bumper might deform from the heat, cool the rear with a fan.
IDENTIFICATION NUMBER LOCATIONS Vehicle Identification Number (VIN) Chassis Number Engine Identification Number VIN: Chassis: EIN: Notes: (w) RX8-General Info Page 18
SCHEDULED MAINTENANCE Scheduled Maintenance Table Schedule 1 : (Normal driving conditions) U.S.A. • The vehicle is mainly operated where none of the "unique driving conditions" apply. Number of months or kilometers (miles), whichever comes first Months 6 12 18 24 30 36 42 48 × 1000 km 12 24 36 48 60 72 84 96 × 1000 miles 7.5 15 22.5 30 37.5 45 52.
Cabin air filter (If installed) Replace every 40,000 km (25,000 miles) or 24 months Chart symbols I Inspect and repair, clean, adjust, or replace if necessary. R Replace L Lubricate C Clean Remarks • • After the described period, continue to follow the described maintenance at the recommended intervals. Refer below for a description of items marked * in the maintenance chart.
Air cleaner element C C R C IGNITION SYSTEM Spark plugs R FUEL SYSTEM Fuel filter Replace every 160,000 Km (100,000 miles) Fuel lines, hoses and connections *1 I I I I COOLING SYSTEM Cooling system Replace at first 96,000 km (60,000 miles) or 48 months; Engine coolant after that, every 24 months.
*1 : According to state / provincial and federal regulations, failure to perform maintenance on these items will not void your emissions warranties. However, Mazda recommends that all maintenance services be performed at the recommended time or mileage / kilometer period to ensure long-term reliability. *2 : Check the tire repair fluid expiration date every year when performing the periodic maintenance. Replace the tire repair fluid bottle with new one before the expiration date.
Rear differential oil R Driveshaft dust boots I Bolts and nut on chassis & body Body condition (for rust, corrosion and perforation) T T R I T T I I T T T T R R R R Inspect annually Inspect at first 80,000 km (50,000 miles) or 48 months; Exhaust system heat shields after that every 40,000 km (25,000 miles) or 24 months 7 Flat tire repair kit * Inspect every year AIR CONDITIONER SYSTEM Cabin air filter (If installed) R R R R Chart symbols I Inspect: Inspect and clean, repair, ad
Remarks • • • To ensure efficient operation of the engine and all systems related to emission control, the ignition and fuel systems must be serviced regularly. It is strongly recommended that all servicing related to these systems be done by an authorized Mazda Dealer. After the prescribed period, continue to follow the described maintenance at the recommended intervals. Refer below for a description of items marked* in the maintenance chart.
PRE-DELIVERY INSPECTION Pre-Delivery Inspection Table Exterior INSPECT and ADJUST , if necessary, the following items to specification: Glass, exterior bright metal and paint for damage Wheel lug nuts All weatherstrips for damage or detachment Tire pressures Headlight cleaner and fluid level (if equipped) Operation of hood release and lock Operation of trunk lid and fuel-filler lid opener Door operation and alignment including side door and back door Headlight aiming INSTALL the following parts: Flap (front
Differential oil level Interior INSTALL the following items: Fuse for accessories INSPECT the operations of the following items: Seat controls (slide and recline) and headrests Folding rear seat Door locks, including childproof door locks Seat belts and warning system Ignition switch and steering lock Transmission range switch Warning buzzers Ignition key reminder alarm Air bag system using warning light Cruise control system (if equipped) Power door lock Shift-lock system (if equipped) Starter interlock A
Heater, defroster, and air conditioner at various mode selections (if equipped) INSPECT the following items: Presence of spare fuse Upholstery and interior finish INSPECT and ADJUST , if necessary, the following items: Operation and fit of windows Pedal height and free play of clutch pedal Parking brake Under hood engine running at operating temperature INSPECT the following items: Automatic transmission fluid level Operation of idle-up system for electrical load, air conditioner or power steering (if eq
Operation of gauges Squeaks, rattles, and unusual noises Engine general performance Emergency locking retractors and automatic locking retractors Cruise control system (if equipped) Operation of meters and gauges, squeaks, rattles, and abnormal noises After road test INSPECT for necessary owner information materials, tools, and spare tire in vehicle The following items must be completed just before delivery to your customer.
JACKING POSITIONS, VEHICLE LIFT (2 SUPPORTS) AND SAFETY STAND (RIGID RACK) POSITIONS Jacking Positions WARNING: • Improperly jacking a vehicle is dangerous. The vehicle can slip off the jack and cause serious injury. Use only the correct front and rear jacking points and block the wheels. • Use safety stands to support the vehicle after it has been lifted. Front • At the center of the front crossmember. Rear • At the center of the differential.
WARNING: • Unstably lifting a vehicle is dangerous. The vehicle can slip off the lift and cause serious injury and/or vehicle damage. Make sure that the vehicle is on the lift horizontally by adjusting the height of support at the end of the arm of the lift. Safety Stand Positions Front and rear • Both sides of the vehicle, on side sills.
TIEDOWN HOOK CAUTION: • Do not use the tiedown hooks under the front and rear for towing. They are designed ONLY for tying down the vehicle when it is being transported. Using them for towing will damage the bumper. 1. Remove the tiedown eyelet from trunk. 2. Wrap a lug wrench with a soft cloth to prevent damage to the bumper and open the cap located on the front and rear bumper. Click here CAUTION: The cap cannot be completely removed.
4. Hook the tying rope to the tiedown eyelet. Click here CAUTION: • If the tiedown eyelet is not securely tightened, it may loosen or disengage from the bumper when tying down the vehicle. Make sure that the tiedown eyelet is securely tightened to the bumper.
TOWING Towing • Proper lifting and towing are necessary to prevent damage to the vehicle. State and local laws must be followed. • A towed vehicle usually should have its rear wheels off the ground. If excessive damage or other conditions prevent this, use wheel dollies. CAUTION: • Do not tow the vehicle pointed forward with driving wheel on the ground. This may cause internal damage to the transmission. CAUTION: • Do not tow with sling-type equipment. This could damage your vehicle.
ELECTRICAL SYSTEM Electrical Parts Battery cable • Before disconnecting connectors or removing electrical parts, disconnect the negative battery cable. Wiring harness • To remove the wiring harness from the clip in the engine room, pry up the hook of the clip using a flathead screwdriver. CAUTION: • Do not remove the harness protective tape. Otherwise, the wires could rub against the body, which could result in water penetration and electrical shorting.
Disconnecting connectors • When disconnecting connector, grasp the connectors, not the wires. • Connectors can be disconnected by pressing or pulling the lock lever as shown. Locking connector • When locking connectors, listen for a click indicating they are securely locked. Inspection • When a tester is used to inspect for continuity or measuring voltage, insert the tester probe from the wiring harness side.
• Inspect the terminals of waterproof connectors from the connector side since they cannot be accessed from the wiring harness side. CAUTION: • To prevent damage to the terminal, wrap a thin wire around the tester probe before inserting into terminal.
Terminals Inspection • Pull lightly on individual wires to verify that they are secured in the terminal. Replacement • • Use the appropriate tools to remove a terminal as shown. When installing a terminal, be sure to insert it until it locks securely. Insert a thin piece of metal from the terminal side of the connector and with the terminal locking tab pressed down, pull the terminal out from the connector. Sensors, Switches, and Relays • Handle sensors, switches, and relays carefully.
Wiring Harness Wiring color codes • • Two-color wires are indicated by a two-color code symbol. The first letter indicates the base color of the wire and the second the color of the stripe.
Fuse Replacement • When replacing a fuse, be sure to replace it with one of the same capacity. If a fuse fails again, the circuit probably has a short and the wiring should be inspected. Be sure the negative battery terminal is disconnected before replacing a main fuse. • When replacing a pullout fuse, use the fuse puller. • Direction of View for Connector • • • The viewing direction of connectors is indicated with a symbol.
Part-side connector The viewing direction of part-side connectors is from the terminal side. * Part names are shown only when there are multiple connector drawings. Vehicle harness-side connector The viewing direction of vehicle harness-side connectors is from the harness side. * Part names are shown only when there are multiple connector drawings.
Electrical Troubleshooting Tools Jumper wire CAUTION: • Do not connect a jumper wire from the power source line to a body ground. This may cause burning or other damage to wiring harnesses or electronic components. • A jumper wire is used to create a temporary circuit. Connect the jumper wire between the terminals of a circuit to bypass a switch. Voltmeter • The DC voltmeter is used to measure circuit voltage.
CAUTION: • Do not connect the ohmmeter to any circuit where voltage is applied. This will damage the ohmmeter. • The ohmmeter is used to measure the resistance between two points in a circuit and to inspect for continuity and short circuits. Precautions Before Welding A vehicle has various electrical parts. To protect the parts from excessive current generated when welding, be sure to perform the following procedure. 1. Turn the ignition switch to the LOCK position. 2. Disconnect the battery cables. 3.
SAE STANDARDS • In accordance with new regulations, SAE (Society of Automotive Engineers) standard names and abbreviations are now used in this manual. The table below lists the names and abbreviations that have been used in Mazda manuals up to now and their SAE equivalents.
EGR Exhaust Gas Recirculation TP sensor Throttle Position Sensor FC Fan Control TCC Torque Converter Clutch FF Flexible Fuel 4GR Fourth Gear TCM Transmission (Transaxle) Control Module GEN Generator TR Transmission (Transaxle) Range GND Ground TC Turbocharger HO2S Heated Oxygen Sensor VSS Vehicle Speed Sensor VR Voltage Regulator IAC Idle Air Control VAF sensor Volume Air Flow Sensor IAT Intake Air Temperature KS Knock Sensor WU-TWC Warm Up Three Way Catalytic Converter
ABBREVIATIONS ABS Antilock Brake System ACC Accessories ALR Automatic Locking Retractor API American Petroleum Institute APV Auxiliary Port Valve AT Automatic Transmission ATF Automatic Transmission Fluid CAN Controller Area Network CCM Comprehensive Component Monitor CM Control Module CPU Central Processing Unit DC Drive Cycle DSC Dynamic Stability Control DTC Diagnostic Trouble Code EBD Electronic Brakeforce Distribution ELR Emergency Locking Retractor EPS Electric Power S
M Motor MAX Maximum MIN Minimum MSP Multi Side Port MT Manual Transmission P/W CM Power Window Control Module RF Right Front RH Right Hand RP1 Rear Primary 1 RP2 Rear Primary 2 RR Right Rear RS Rear Secondary SAS Sophisticated Air Bag Sensor SAE Society of Automotive Engineers SST Special Service Tool SSV Secondary Shutter Valve SW Switch T/F Trailing Front TCS Traction Control System TFT Transmission Fluid Temperature TNS Tail Number Side Lights TPMS Tire Pressure M
UNITS Electric current A (ampere) Electric power W (watt) Electric resistance ohm Electric voltage Length V (volt) mm (millimeter) in (inch) kPa (kilo pascal) Negative pressure mmHg (millimeters of mercury) inHg (inches of mercury) kPa (kilo pascal) Positive pressure kgf/cm2 (kilogram force per square centimeter) psi (pounds per square inch) Number of rpm (revolutions per minute) revolutions N·m (Newton meter) kgf·m (kilogram force meter) Torque kgf·cm (kilogram force centimeter) ft·lbf (foot pound
Upper and Lower Limits • o o • When the data indicates upper and lower limits, the converted values are rounded down if the SI unit value is an upper limit and rounded up if the SI unit value is a lower limit. Therefore, converted values for the same SI unit value may differ after conversion. For example, consider 2.7 kgf/cm2 in the following specifications: 210260 kPa {2.12.7 kgf/cm2 , 3038 psi} 270310 kPa {2.73.2 kgf/cm2 , 3945 psi} The actual converted values for 2.7 kgf/cm2 are 264 kPa and 38.
INSTALLATION OF RADIO SYSTEM • If a radio system is installed improperly or if a high-powered type is used, the CIS and other systems may be affected. When the vehicle is to be equipped with a radio, observe the following precautions: Install the antenna at the farthest point from control modules. Install the antenna feeder as far as possible from the control module harnesses. Ensure that the antenna and feeder are properly adjusted. Do not install a high-powered radio system.
